Expert System Framework for Vertical Roller Mills Start-Up Automation in Cement Manufacturing

Vertical Roller Mills (VRMs) are extensively used in the cement industry for their high energy efficiency. Nonetheless, the start-up phase remains a critical operational challenge due to its pronounced sensitivity to changing process conditions. Such variations frequently induce excessive vibrations, which can trigger unplanned shutdowns, mechanical damage, and diminished throughput. The underlying cause lies in the intrinsic variability of raw materials, particularly in parameters such as moisture, particle size distribution, and hardness, which exert a direct influence on the mill’s dynamic response during the transition to steady-state operation. This study presents the real-world implementation of an Expert System designed to automate the start-up sequence. By applying logical reasoning to key process setpoints, the system enables a controlled and gradual ramp-up, minimizing transient instabilities. Seamlessly integrated into the plant’s control infrastructure, it facilitates remote unattended operation, enhancing process reliability and operational efficiency. The proposed architecture addresses a key challenge in cement production and enables advanced control and intelligent optimization.